1. RISK ASSESSMENT

1.1. HAZARD IDENTIFICATION

In practical terms, hazard identification is a thorough look at the workplace and processes to identify

those things, situations, processes that may cause harm, particularly to the working force and nearby

population. After identification of the potential hazards, one has to evaluate its potential to cause harm

and then decide what type of control measures shall be taken to control it from the happening. Hazard

identification is a very important tool as it is an integral part of a good occupational health and safety

management plan. The aim of the hazard identification process is to reduce the level of risk by taking

precautions or initiating control during project execution.

The various hazard analysis techniques that may be applied are Hazard and Operability (HAZOP) studies,

Fault – Tree Analysis (FTA), event –tree analysis and failure and effects mode analysis.

1.2. Hazard Identification & Risk Assessment (HIRA)

The purpose of a Hazard Identification and Risk Assessment (HIRA) is to understand what risks or threats

to public safety, property or the environment exist.

Figure 1 Hazard Identification & Risk Assessment (HIRA) process

Hazard Identification and Risk Assessment (HIRA) Process,

Identification of hazards

Analyze or evaluate the risk associated with the hazards

Determine appropriate ways to eliminate or control the hazards

Evaluate the likelihood of an injury or illness occurring, and its severity

Review of all available health and safety information about the hazard including MSDS,

manufacturer’s literature, information from organizations and results of testing

Identify actions necessary to eliminate or control the risk

Monitoring to confirm the risk is controlled

Keep any documentation or records that may be necessary. Documentation may include detailing the

process used to assess the risk, outlining any evaluations, or detailing how conclusions were made.

1.3. Identification Hazard

Details of the major anticipated risks from the Hazards is given in below

Table 1 Hazards of the proposed plant

Sr.

No. Name Description Severity Hazard

1 Transportation of raw

material

Molasses Major Exposure

Coal Major --

Yeast, urea Minor Exposure &

inhalation

Sulphuric acid, Di-ammonium

Phosphate, Antifoam reagent,

Caustic soda

Major Exposure &

inhalation

2 Storage of

Molasses Products

and byproducts

Molasses, RS/ ENA/

Technical Alcohol, fusel oil

Major Explosive, Fire

3 Manufacturing

process

Fermentation Major Fire

Distillation Unit Major Heat & Fire

Power Plant Major Heat fire &

4 Utilities D.G set, Boiler, Turbine Major electrocution

5 Other accidents Leakages from the vessels,

Catastrophic rupture of

pressure vessels and

Storage Tanks

Major Exposure & Fire

1.4. RISK ASSESSMENT

Risk analysis deals with the identification and quantification of risks, the plant equivalent and personnel

are exposed to, due to accidents resulting from the hazards present in the factory. Risk classification is

given in following Table 2

Table 2 Risk classification and score table

1.4.1. Potential risk and mitigation measures for during construction phase

Existing factory has maintained the risk associated with the operational component. Following are the

general risk assessment and mitigation measures associated with proposed project operation. Risk impact

and mitigation measures during the construction phase are shown in Table 3

Table 3 Risk Impact and rating matrix during the construction phase

Sr.

No.

Activity Associated

Hazards

Health

impact

Risk

rating

Proposed mitigation & control

measures

1 Site Leveling Vehicular

movement,

Insect/snake bite

Physical

injury,

and organ

damage

M Providing PPEs to

workers

Appointing the

qualified persons for

the particular job.

Speed limit control

Providing Training

2 Loading and

Unloading of

material

Accidents Physical

Injury

M Providing PPEs to workers

Training to workers

3 Excavation Falling

objects

or objects near

an excavation.

Slips, trips,

and falls

Property

Loss

Physical

injury

M Work Permit System will be

followed.

Excavated material will

be stacked safely.

Area will be barricaded

Training to workers

PPEs will be provided

4 Construction Structure

may

fall down

Workers

may

fall down

from the height.

Physical

Injury

Physically

handicapped

Property

Loss

H Work Permit System will be

followed.

Height work permit will be

issued to the person.

Safety belt will be provided to

workers Training to workers

5 Cutting and

Welding

Fire or

explosion

Electric shock

from electrical

welding

Physical

Injury

Burn Injury

Property

loss

H Standards Work Procedure

Training will be provided

Proper PPE will be provided.

Regular monitoring of electrical

equipment’s to avoid loose

connection

Area will be barricaded

6 Installation of

Machinery.

Structure may

collapse

Property

loss

Physical

Injury

M Only authorized personnel will

operate the machine

The appropriate platform will

be designed as per the load

bearing calculation.

1.4.2. Potential risk and mitigation measures during the operation phase

1.4.2.1. Boiler Operation

The potential risk and its mitigation measures for Boiler operation is given in Table.4

Table 4 Risk Impact and rating matrix for Boiler operation

Sr.

No. Activity

Associated

Hazards

Health

impact

Risk

rating Proposed mitigation & control measures

1 Working

near Boiler

High noise Noise-

induced

hearing

loss

M Required PPE need to be used

2 Boiler

maintenance

Mechanical

hazard

Physically

injury

M PPEs

Regular monitoring for checking

leakages

Individual vigilance and proper training

to the workers for proper handling

Provision of First aid box

3 High

Pressure

Steam

Explosive Risk of

severe

injury,

damage to

equipment

H Required PPEs

Good housekeeping

Regular monitoring of the storage facility

Flammable chemicals stored away from

the source of ignition

Firefighting facility Provision of First aid

Box

4 Incomplete

Combustion

Asphyxiati

on

from

carbon

monoxide

Possible

fatality

H Online CO monitors Regular checking of

Workplace Individual alertness and

precaution

5 Maintenance

work

Slips, Trips

and Falls

Physical

injury

M PPEs

Individual alertness and precaution

6 Electrical

maintenance

work

Electricity Electric

shock,

Possible

burns

H PPEs

Regular checking and maintenance of

electrical units

Provision of first aid box

7 Maintenance

of burner

Burn injury Severe

physical

injury or

burn

M PPEs will be provided

Work will be carried out under proper

supervision.

Individual alertness and precaution is

important

Follow of SOPs

Provision of first aid box

1.4.2.2. Risk during Electrical Transformer

Table 5 Risk during Electrical Transformer

Sr.

No. Activity

Associated

Hazards Health impact

Risk

rating

Proposed mitigation & control

measures

1

Electrical

Transformer-

Electrical

shock and

fire

Fire, shock,

burn

Severe

Physical

injury or

burn, Death

H Cut off the power supply

Treat the injured for electrical

shock If the fire is caused,

immediately fight fire with

available resources, summoning

outside help if necessary

1.4.2.3. Risk during D.G. set operation

Table 6 Risk Impact and rating matrix for D.G. set operation

Sr.

No.

Activity Associated

Hazards

Health impact Risk

rating

Proposed mitigation & control

measures

1 Working

near DG

High noise Noise-induced

hearing loss

M Use of PPE

Acoustic enclosure

2 Maintenan

ce

Fire Burns,

Serious injury

H Use of PPE

Restricted entry

Use of flameproof fittings

3 HSD

storage

Leakage/Fire Risk of severe

physical injury

and burn

H PPEs will be provided

First aid box

Regular monitoring to check the

leakage and spillage

storage facility

Storage will be away from the

ignition source

Firefighting facility will be

provided

4 DG set

maintenan

ce

Mechanical

Hazard

Physical injury M PPEs

First aid box at the approachable

place

Leakage and heat in the joint will

be checked before maintenance

1.4.2.4. Hazard & associated Risk of storage and handling of raw material

Impact matrix for risk associated with storage and handling of the material is given in Table 7. Various

material and its storage/capacity details are given Table 9.

Table 7 Impact matrix of Storage and handling of raw material

Sr.

No.

Activity Associated

Hazards

Health

impact

Risk

rating

Proposed mitigation & control

measures

1 Storage,

handling,

loading &

Unloading of

material

Exposure,

leakage,

Fire,

Explosion

Physical

Injury,

burn, Eye

irritation

and

respiratory

problem

H Provision of Eyewash

Inspection and regular monitoring

of storage area

Training to Workers for proper

handling

PPEs will be provided as Nose

mask, Hand gloves.

A proper system for loading

operation to prevents spillage

Provision of level indicators for

Storage Tanks

Spill kit for Acid and other

chemicals

Proper ventilation

First Aid boxes

2 Transportation Fire,

Accident,

leakage

Burns,

Serious injury

H Firefighting facility

Training to Driver

MSDS

TREM Card

First Aid Box

1.4.2.5. Hazard & associated Risk of Molasses storage tank

Molasses can ferment if excessive moisture contamination is allowed. Fermentation can yield carbon

dioxide with possible traces of ethanol or volatile fatty acids (e.g. acetic, propionic, lactic, or butyric) and

if exposed to a spark or flame may result in an explosion. Fermentation may also occur in dilute surface

layers formed by condensation from the headspace above the liquid.

Table 8 Impact matrix of storage of molasses

Sr.

No.

Activity Associated

Hazards

Health impact Risk

rating

Proposed mitigation & control

measures

1 Storage and

Handling

Explosion May cause

slight

irritation

May cause

irritation

H Proper ventilation shall be

provided

Inspection and regular

monitoring of storage area

Training to Workers for

proper handling

PPEs will be provided as

Nose mask, Hand gloves.

Provision of level indicators

Sr.

No.

Activity Associated

Hazards

Health impact Risk

rating

Proposed mitigation & control

measures

for Storage Tanks

If causes eye irritation wash

area with soap, flood eye with

water and water

Table 9 Storage Tanks/Area/Capacity details

Sr. No. Material Storage capacity

1 Water 32110 CMD

2 Molasses Storage tanks 5 Each of capacity 6000 MT

3 Bagasse 20000 m2 Bagasse yard area & Capacity 114800 MT

4 Pressmud Press mud yard 500 m2 & capacity 10000 MT

5 Coal Coal shed existing Nil & For proposed Area 1000 m2, Capacity

8400 MT

6 Ash 500 m2, Capacity 200 MT

7 Spentwash storage Spentwash generated from 45 KLPD Stored in lagoon having 30

days spentwash storage capacity (8100 m3 spentwash per month).

Composting principle treatment for spentwash generated from 45

KLPD distillery.

Spentwash generated from 100 KLPD Stored in proposed lagoon

having 7 days spentwash storage capacity (1400 m3 spentwash

per 7 days). Concentration and incineration treatment for

spentwash generated from 100 KLPD distillery.

8 Alcohol Existing 1350000 Liter &Total storage after proposed expansion

would be around 4350000 Liter

9 Other raw material storage 500 m2 area with 10 MT capacity

1.4.2.6. Risk associated with alcohol storage and its mitigation measures

Impact matrix of risk associated with storage and transportation of alcohol along with control and

mitigation measures are given in Table 10

Table 10 Impact matric of risk associated Alcohol storage

Sr.

No.

Activity Associated

Hazards

Health impact Risk

rating

Proposed mitigation & control

measures

1 Storage

of

Alcohol

Exposure,

inhalation,

ingestion

& Fire

Exposure to over

1000 ppm may

cause a headache,

drowsiness and

lassitude, loss of

appetite, and

inability to

concentrate.

Throat Irritation

H Storage

Storage will be away from

process area with good

ventilation. Avoid all possible

sources of ignition like spark or

flame.

Use spark/flame proof hand tools

Electrical wiring will be

flameproof type

Sr.

No.

Activity Associated

Hazards

Health impact Risk

rating

Proposed mitigation & control

measures

Ingestion causes

depression of the

central nervous

system, nausea,

vomiting, and

diarrhea

Liquid or vapor

may cause eye and

skin irritation

Burn injury

Based on the leakage quantity,

wiped out with or dilute by

spraying the water to suppress

the vapors

Control measures in case of

overexposure

If the victim is conscious and

able to swallow, then give water

or milk to drink to dilute the

contents in the stomach

Look out for medical help Skin

or Eye exposure

immediately flush affected area

with plenty of water. Eyes should

be flushed for at least 15 minutes

with water

PPEs will be provided to avoid

exposure

1.4.2.7. Risk associated with the work area of distillation

Table 11 Impact matrix of risk associated distillation area

Sr.

No.

Activity Associated

Hazards

Health

impact

Risk

rating

Proposed mitigation & control

measures

1 Working near

Distillation

column

Heat & Fire Physical

injury &

burning

H PPEs

Firefighting facility

First aid box

Periodic checking of all parts

Table 12 Alcohol Warning Information for Ethyl

Alcohol Section

Product Name Ethyl Alcohol,

Synonyms Anhydrous Ethyl Alcohol, Dehydrated Alcohol

Chemical Family Alcohol

Molecular Weight 46.07

Formula CH3CH2OH

Health Fire Reactive Other Degree of Hazard Colour Coding Other Codes

0 3 0 - 0 = Minimum Health = Blue Ox = Oxidiser

1 = Slight Fire = Red Acid = Acid

Health Fire Reactive Other Degree of Hazard Colour Coding Other Codes

2 = Moderate

3 = Serious

Reactivity =

Yellow

Alk = Alkaline

COR = Corrosive

4 = severe Other = White W = No use water

SECTION II – INGREDIENTS

COMPOSITION CAS RN. NOMINAL

WT/WT% PEL/TLV HAZARD

Ethyl Alcohol 64-17-5 100.0 1000 ppm Flammable/Nervous System

Depressant

PEL = Personal Exposure Limit

TLV = Threshold Limit Value

SECTION III-HEALTH

INFORMATION

INHALATION Exposure to over 1000 ppm may cause headache, drowsiness and

lassitude, loss of appetite, and inability to concentrate. Irritation of the

throat.

INGESTION Can cause depression of central nervous system, nausea, vomiting, and

diarrhea.

EYE CONTACT Liquid or vapor may cause irritation.

SKIN CONTACT May cause irritation and defatting of skin on prolonged contact.

SECTION IV – OCCUPATIONAL EXPOSURE LIMITS

PEL (OSHA Permissible Exposure

Limit): Mixture

See Section II

TLV (ACGIH Threshold Limit

Value): Mixture

See Section II

SECTION V – EMERGENCY FIRST AID PROCEDURE

FOR OVEREXPOSURE BY

SWALLOWING

If victim is conscious and able to swallow, have victim drink water or

milk to dilute. Never give anything by mouth if victim is unconscious or

having convulsions. CALL A PHYSICIAN OR CHEM-TREC

(POISON CONTROL) IMMEDIATELY. Induce

vomiting only if advised by physician (Poison Control)

INHALATION Immediately remove victim to fresh air. If victim has stopped breathing,

give artificial respiration, preferably mouth-to- mouth. GET MEDICAL

ATTENTION IMMEDIATELY

CONTACT WITH EYES OR

SKIN

Immediately flush affected area with plenty of cool water. Eyes should be

flushed for at least 15 minutes. Remove and wash contaminated clothing

before reuse. GET MEDICAL ATTENTION IMMEDIATELY

SECTION VI – PHYSICAL DATA

BOILING POINT 173° F (78 0C)

MELTING POINT -173° F (-114 0C)

VAPOR PRESSURE 44.6 mm Hg @ 68° F (20 0C)

SPECIFIC GRAVITY 0.7940 @ 60°/60° F

VAPOR DENSITY (AIR = 1) 1.59

SOLUBILITY IN WATER Complete in water, chloroform, acetone, ether, benzene and methanol

APPEARANCE AND COLOR Clear and colorless, volatile liquid with a weak, vinous, alcohol odour and

bitter taste. Odour threshold = 84 ppm

SECTION VII – FIRE AND EXPLOSIVE HAZARDS

FLASH POINT 56° F ASTM D-56 (Tag Closed Cup)

AUTO-IGNITION

TEMPERATURE

685° F

FLAMMABLE LIMITS IN AIR,

% BY VOLUME

LOWER: 3.3 UPPER: 19

NFPA (National Fire Protection HEALTH (0) FIRE (3) REACTIVITY (0)

Association) RATING

FIRE FIGHTING PROCEDURES (Note: Individuals should perform only those fire-fighting procedures

for which they have been trained.) Use dry chemical, “alcohol” foam,

or carbon dioxide; water may be ineffective, but water should be used to

keep fire-exposed containers cool. If a leak or spill has not ignited, use

water spray to disperse the vapors and to protect men attempting to stop a

leak. Water spray may be used to flush spills away from exposures and to

dilute spills to nonflammable mixtures.

Firefighters should wear self-contained breathing apparatuses in the

positive pressure mode with a full-face piece when there is a possibility of

exposure to smoke, fumes, or hazardous decomposition products.

SECTION VIII – REACTIVITY

STABILITY Generally stable.

HAZARDOUS

POLYMERIZATION

Not likely.

CONDITIONS & MATERIALS

TO AVOID

Contact with acetyl chloride and a wide range of oxidizing agents may

react violently.

SECTION IX – EMPLOYEE PROTECTION

CONTROL MEASURES Handle in the presence of adequate ventilation.

RESPIRATORY

PROTECTION

Where exposure is likely to exceed acceptable criteria, use

NIOSH/MSHA approved respiratory protection equipment. Respirators

should be selected based on the form and concentration of contaminant in

air and in accordance with OSHA (29 CFR 1910.134).

PROTECTIVE CLOTHING Wear gloves and protective clothing, which are impervious to the product

for the duration of the anticipated exposure if there is potential for

prolonged or repeated skin contact.

EYE PROTECTION Wear safety glasses meeting the specifications of ANSI Standard Z87.1

where no contact with the eye is anticipated. Chemical safety goggles

meeting the specifications of ANSI Standard Z87.1 should be worn

whenever there is the possibility of splashing or other contact with the

eyes.

SECTION X – ENVIRONMENTAL PROTECTION

ENVIRONMENTAL

PRECAUTIONS

Avoid uncontrolled releases of this material.

Where spills are possible, a comprehensive spill response plan should be

developed and implemented.

SPILL OR LEAK PROCEDURES Wear appropriate respiratory protection and protective clothing as

described in Section IX. Contain spilled material. Transfer to secure

containers. Where necessary, collect using absorbent media. In the event

of an uncontrolled release of this material, the user should determine if

the release is reportable under applicable laws and regulations.

WASTE DISPOSAL All recovered material should be packaged, labeled, transported, and

disposed off, or reclaimed in conformance with applicable laws and

regulations and in conformance with good engineering practices.

SECTION XI HANDLING AND STORAGE

Precautions

Keep locked up. Keep away from heat. Keep away from sources of ignition. Ground all equipment containing

material. Do not ingest. Do not breathe gas/fumes/ vapor/spray. Wear suitable protective clothing. In case of

insufficient ventilation, wear suitable respiratory equipment. If ingested, seek medical advice immediately and

show the container or the label. Avoid contact with skin and eyes. Keep away from incompatibles such as

oxidizing agents, acids, alkalis, and moisture.

Storage

Store in a segregated and approved area. Keep container in a cool, well-ventilated area. Keep container tightly

closed and sealed until ready for use. Avoid all possible sources of ignition (spark or flame). Do not store

above 230C (73.4

0F)

1.5. SAFETY MEASURES RECOMMENDATION

1.5.1. Storage and material handling area

Proper ventilation shall be provided

Area will be marked as “No smoking Zone”

Use of proper PPEs

Pressure relief valves shall be provided

Provision of Safety valves and rupture disk

Provision of fire hydrant system along with other portable fire extinguishers

Adequate distance between the storage Tanks

Provision of dyke wall to the Tanks

Proper earthling to the Tanks

1.5.2. Reactor Safety

Provision will be made for temperature & pressure indicators

Heating & cooling Jacket will be provided to maintain the temperature

Pressure switch with hooter shall be provided

Pressure safety valve will be provided

Double earthling shall be provided

1.5.3. DG Sets

Acoustic enclosures to be provided

Entry near the unit shall be restricted

Qualified and highly trained engineers shall be appointed

1.5.4. Boiler

Work permit system will be evolved and will be followed during maintenance work

Proper ventilation shall be maintained

Entry shall be allowed only after proper checking of gases, if any

Worker should be trained properly

Working should be under supervision of qualified and trained personnel

1.5.5. Storage and Handling of Alcohol

Keeping away from oxidizers, heat and flames.

Avoidance of plastics, rubber and coatings in the storage area.

Cool, dry, and ventilated storage and closed containers.

Leakage should be washed out and diluted.

Regular monitoring and maintenance to avoid leakages.

If major leakage in tanks can be mitigated by transferring the material to other tank.

Grounding of the container and transferring of equipment to eliminate static electric sparks. In case of

any emergency following measures would be taken:

First Aid Measures

Use of extinguishing media surrounding the fire as water, dry chemicals (BC or ABC powder), sand,

dolomite, etc.

Foam system for fire fighting will be provided to control fire from the alcohol storage tank. The foam

thus produced will suppress fire by separating the fuel from the air (oxygen), and hence avoiding the

fire and explosion to occur in the tank. Foam would blanket the fuel surface smothering the fire. The

fuel will also be cooled by the water content of the foam. The foam blanket suppresses the release of

flammable vapors that an mix with the air.

Special Fire Fighting Procedures; Keeping the fire upwind. Shutting down of all possible sources of

ignition, keeping of run-off water out of sewers and water sources. Avoidance of water in straight

hose stream which will scatter and spread fire. Use of spray or fog nozzles will be promoted, cool

containers will be exposed to flames with water from the side until well after the fire is out.

1.5.6. Molasses storage

Store in good quality ventilated and leak-proof tanks (mild steel, stainless steel, polyethylene, PVC)

at ambient temperatures, out of moisture.

Continuous mixing of molasses should be done.

If there is increase in temperature beyond 300C external cooling of tanks should be provided. A

temperature recorder should be provided to the tanks.

Avoid microbiological contamination or dilution with water.

Regular monitoring and maintenance to avoid leakages.

1.5.7. Building & workspace

Adequate space will be provided for equipment repair or removal

Equipment maintenance shops will be set up with appropriate safety provisions for hazards associated

with maintenance activities

Lightning protection will be provided

1.5.8. Electric items

Medium and high voltage cables will be completely enclosed

Electrical equipment will be grounded adequately

Wiring will be properly insulated, grounded, and non-exposed

Emergency shutoff switch, clearly labelled, at all machinery units will be provided

DG set will be provided as stand by source of power

Maintenance tools with insulated handles will be provided

1.5.9. Fire

The fire protection system is to provide for early detection, alarm, containment and suppression of fires.

The complete fire protection system will comprise of the following. Fire hydrant network will be

provided for firefighting in the entire project area along with following firefighting equipment will be

provided

Different type of Fire Extinguishers, Detectors and fire Alarm shall be provided.

Fire hydrant system

Fire Tender with chemicals foam and required arrangement for firefighting to control the fire from the

alcohol storage

Foam system shall be contain aqueous film forming compound of 3 to 6% alcohol resistance foam

concentrated with ISI mark 4889

Water storage Tank exclusively for firefighting operation

Rubber mat will be used near panel area

Periodical training to the identified supervisors and Employees in the field of Firefighting and safety

Emergency exits at specific locations and will be marked on the layout

Cautionary note, safety posters, stickers will be displayed at appropriate locations

First Aid boxes will be made available at appropriate locations

Emergency Control Center Provision shall be made to establish an Emergency Control Centre (ECC)

from which emergency operations are directed and coordinated. This center is activated as soon as

on–site emergency is declared. ECC is equipped with adequate communication systems in the form of

telephones (Emergency telephone numbers.) and other equipment’s to allow unhampered

organizations and other nearby facility personnel.

1.5.10. Occupational health hazard and safety measures

During operation handling of chemicals and other material used, a practice of preventive maintenance

shall be adopted to take care of employee’s health. The various safety equipment such as breathing

apparatus, gum boots, goggles and helmets will be provided to the workers/operators. Besides, all the first

aid, firefighting devices will also be inspected, tested and maintained periodically so that it is available in

ready to use condition. Provision of pre- medical and periodical health check-up for all the employees

shall be implemented and record maintained. If any abnormality is noticed due to occupational exposure,

necessary Treatment will be assured from qualified physician. Following measures shall be implemented

to avoid the occupational hazards to the employees:

Regular housekeeping of the entire plant area

Regular or preventive maintenance of floor, platforms, staircases and passages to avoid the slip

incident

Provision of obstruction free walkways and workplace

Periodical training to the employees for the proper operation of the plant and various processes

Restricted entry into the plant premises

Checking and calibration of all Instruments and Fire Devices to keep them in proper operating

conditions

Installation of Electrical devises as per the prescribed standards

Provision of D.G. Sets to avoid the complication during power failure

Provision of required fire Extinguishers at different locations for easy access

Provision of lighting Arrester

Various types of PPEs like breathing apparatus, ear muffs, earplug, masks, leather hand gloves;

asbestos hand gloves; acid/alkali proof rubber hand gloves; electrical resistance hand gloves and gum

boots, goggles and helmets will be made available

Provision of First aid Boxes and periodical checking for required medicine and other material to take care

of superficial bodily injuries during work

Figure 2 First Aid Box facility placed properly in the required location

1.6. DISASTER MANAGEMENT PLAN (DMP)

A disaster is an unforeseen combination of circumstances that cause serious body injuries, loss of life or

extensive damage to the plant, Machinery or to the environment. Existing factory has prepared a details

Disaster management plan, the following is the generalize disaster management plan recommended for

the proposed project.

Following uncontrollable situation may lead to disaster or plant emergency

1.6.1. Manmade

Plant failure

Rupture or damage of the line, vessel or Tank

Excessive leakage of flammable material

1.6.2. Natural

Cyclone

Earthquake

Flood

Fire

Terrorist attack

A disaster management plan is a written document where all the details regarding the causes of the

disaster are noted along with required control measures. It also gives details about the responsible

personnel shall be available on site during an emergency and their role to control the disaster to a

minimum level or from spreading the outside to protect the plant and machinery including employees and

nearby areas. The DMP to tackle the emergency can be divided into the two parts for the ease of operation

and to effectively control the emergencies within the shortest possible time.

Figure 3 Disaster management process

1.6.3. Onsite Emergency Plan

If an accident/incident takes place and its effects are confined only, then it is termed as an on-site

emergency. It involves employees and other infrastructure within the organization. In this plan, the

company officers and employees are given pre-decided responsibilities to handle the emergency. All other

required resources to tackle this type of emergency are available. The individual employee or designated

persons will be held responsible to take or initiate appropriate action when required. All the

employees/responsible persons required to take or initiate the action at the time of emergency are trained

appropriately so that they can perform their task without any difficulty. To make the handling of

emergencies absolutely perfect, mock drills need to be conducted periodically for a particular scenario.

During mock drills, a particular scenario is simulated to understand the gravity and requirements of

action. During the mock drills, all the important points or happenings are noted and discussed to find out

the lacunae or for the further improvement in the written plan.

1.6.4. Offsite Emergency Plan

If any accident or incident occurred in the premises, man will need help from outside sources because of

the magnitude of emergency then it termed as Offsite Emergency. This offsite emergency cannot be

controlled only by using the internal resources and need timely help from the outside companies or from

the government authorities to tackle such type of emergencies to avoid the loss of property, human health

or environment in and around the premises. An offsite emergency management plan involves government

bodies as well as nearby industries for necessary help and to control the emergency.

1.6.5. Objectives of disaster management

To control the incident or accidents from the happening

To eliminate the emergencies if possible

Prepare for the emergency handling

To see whether required activities are performed in the right order by the individuals or not

To find out the required changes for co-ordinated activities

To reduce the time of activities to control the emergencies

To minimize the effects of the incident on person, property, and environment

Continuous improvement

1.6.6. Onsite Emergency Preparedness Plan

Main elements of on-site Emergency Preparedness Plans are:

Leadership and emergency management cell

Defined role and responsibilities of the key personnel

Emergency actions to be executed by the Members of the Committee

Protective and rescue equipment

Medical care Unit

Training and periodic review

Periodical Mock drills, its monitoring, and analysis to find out the shortcoming for the improvement

List of available firefighting equipment, its maintenance, and records

Training to the committee members and feedback on requirements if any

Line of command

Requirement of Siren and alarm system

Written document

List of available resources with the Company

List of resources available from outside during the emergency

Important phone numbers of authorities

1.6.6.1. Disaster Management Cell

Disaster Management Cell (DMC) consisting of authorized head that will be responsible for the handling

of emergency situations. All the details of team members will be available at the site; their contact details

will be displayed in the plant and will be informed to other employees. DMC will make the employees

understand and aware of the hazards and associated risks that may give rise to an emergency situation at

the plant. DMC will train and inform the employees regarding their role and responsibilities during

emergency and dos and don’ts. Following team of personnel will be required to fulfill their

responsibilities to tackle the emergency.

TEAM A

The distillery In-charge/Occupier along with the manager of each section will be responsible for the

handling of any kind of emergency in the factory. They will inform the concern employees or authorities

about the emergency situation and action that need to be initiated. They will take initiative in directing the

action of the people.

TEAM B

After knowing the emergency situation, in-charge of individual section/department will communicate

with In-charge (Disaster Main Controller) for any specific instruction and then he will guide other

employees of the section to leave the workplace after taking safe shut down. They will be asked to

assemble at Assembly point upwind of the Factory. After reaching the assembly points they should watch

the activities undertaken by Team A and wait for further instruction if any form the Manager. The

Manager / Supervisor will act as an Incident Controller at his Section or the Emergency location and need

to wait for further instruction from Disaster Main Controller

TEAM C

The maintenance In-charge and other maintenance head from each department such as Mechanical

Engineering, Electrical Engineering, Instrumentation and Civil Engineering along with Safety and Fire

will form this Team who will actually fight the situation to control the emergency. All the required

equipment and firefighting accessories will be available at their disposal. They will have all safety

appliances in their custody/use and they will act to minimize the effect of incidence. They will keep

informing the progress to DMC and for want of any help. After the emergency is under control, they will

inform the DMC and DMC will inform all other Teams involved that emergency is under control. The

DMC shall appraise the situation and if found Ok, he will inform control room to declare all clear

sound/siren so that employees can resume the duties.

TEAM D

This Team is mainly concern with the security and outside news and will take the instruction from the

DMC. It will consist of a security department and welfare officer who will be available at the office with

all necessary records including names of Team Members and other required help from outside. They will

have the list of people along with their addresses and telephone numbers. They will keep the records of

important offices of the Government authorities such as Directorate of Industrial Safety and Health,

Boiler Inspector of the factory, Commissioner of Police, local Police station, Fire Brigade, company

Doctors, private Doctors and another important contact which will be helpful during and after the

emergency.

All required facilities shall be made available at a particular location in the Factory for emergency use.

All the personnel involved in an emergency shall proceed or will be brought to the factory. Based on the

information gathered and provided by the incident controller of a particular section where there is

emergency if required emergency shall be declared by the DMC by giving instruction to Team D to sound

the particular Siren. After listening to the sound of Siren, concern person will understand the type and of

emergency and will come prepared at the site of the incident.

During emergency and as per the information received by the DMC from IC, the Team members from the

Rescue team shall look out for the casualties if any on the site and will provide necessary help. The

required medical and other help shall be provided based on the requirement and assessment of the gravity

of the situation. The team will also carry out the headcount if required and as per the instruction of DMC

or the Occupier. Further, the detail shall be provided to outside agencies by the nominated authorized

person from the Factory to avoid the mismatch of the situation so that right message goes to the media.

During an emergency, care shall be taken to avoid the panic situation within and outside the factory

premises or in the general public.

1.6.6.2. Key Personnel

The actions necessary in an emergency will clearly depend upon the prevailing circumstances.

Nevertheless, it is imperative that the required actions are initiated and directed by nominated people,

each having specified responsibilities as part of the coordinated plan. Such nominated personnel is known

as Key Personnel.

The Key Personnel is:

Site Controller (SC)

Incidental Controller (IC)

Liaison and Communication Officer (LCO)

Fire and Security Officer (FSO)

Team Leaders (TL)

1.6.6.3. The requirement of Equipment and Materials

Based on an actual assessment of emergency, there can be a requirement of Extra First Aid personnel

to deal with casualties and need to be provided from outside

All types of PPEs

Emergency engineering works, provision of extra or replacement of light, isolation of equipment,

temporary bypass electrical lines etc.

Assembly point, emergency control center, signboards

Moving Tankers or other vehicles from the area of risk

Fire protection and firefighting facilities

Emergency lighting and standby power

Emergency equipment and rescue equipment

Material safety data sheets for hazardous chemicals

Plan showing hazardous material storage area

List of emergency equipment

List of safety equipment

List of important telephone numbers and addresses

Nearest hospitals and ambulance service center

Nearest fire station

Govt. Officials

Transport provider

Names and address & contact telephone number of key personnel

The onsite emergency plan will be documented and circulated to all concerned for knowledge, study, to

understand and easy follow up. The emergency plan will be rehearsed and practiced at regular intervals

i.e. Mock drills shall be conducted at the suitable interval to test the efficiency of the plan, personnel,

equipment and coordinated efforts to increase the confidence level of personnel during emergencies.

1.6.6.4. Training

Training on fire fighting

Training on spill control

Training on toxic release control

Training on good housekeeping

Training on use of PPEs

1.6.6.5. Communication

Following means of communication will be made available,

Telephones

Walkie-talkies

Mobiles

Public announcement system

Emergency Siren

1.6.7. Offsite Emergency Plan

In case the hazard spreads outside the premises Team A under the instruction of DMC will communicate

to the District Magistrate, Commissioner of the Police and inform the situation as Off-Site Emergency.

Types of emergency facilities/actions required from outside bodies are,

Firefighting facilities required: Factory will have its own firefighting facilities but during an

emergency, fire brigade may be called from nearby areas or other establishments

Police help shall be required during an emergency for control of people, traffic and security

arrangements

Medical help required: seriously injured personnel may be referred to the Hospital/Primary Health

Centre depending upon injuries

1.6.8. Information to authorities

Emergency situations will be informed to the local Panchayat official regarding the likely hazards

from the industry and the steps to be taken when there is an Off-Site Emergency. It is preferable that

the Local Panchayat Officials are also trained on simple protective methods through demonstrations

and practice

District Magistrate, Commissioner of the Police and District Control Room if exist

1.6.9. General Natural Disaster Management Measures

Seismic zone for the proposed project site comes under zone III (6 to 8 Richter scale)

Factory Management shall train their staff to manage emergencies arises from fire, flood, lightning,

and leakages.

As soon as the emergency warning receives from the District Disaster Management Authority, the

raw material, as well as finished products, shall be kept to a minimum to avoid spillage or misuse

All the material and products shall be stored properly to avoid the damage or mixing with other

All the employees will have the list of important phone numbers and contact details to help in getting

the required help in time. These numbers shall be displayed at a distinct location within Factory

premises

Company’s designated person from Team A will be t h e main contact person for all the

employees for any type required help from outside

District level disaster management units

Health & Family Welfare

Medical

Nearest Fire station

Nearest Doctors & Ambulance

Forest & Environment Department

Police Station

Village head & Panchayat

Company’s Emergency Management Cell Members

Transport

Electricity

PWD

Substation details from where Company takes power

Civil Supplies

Animal Husbandry

Agriculture

1.7. CONCLUSION

Project proponent will implement all preventive measures to tackle all type of emergencies arising out of

operation or malfunction of individual unit’s. The required resources for Onsite and Offsite emergency

management plan will be properly planned and provided to implement the plan effectively. The factory

shall give the highest priority towards Health and safety of the employees and people residing in nearby

areas. Management shall conduct the training to the nearby villagers to appraise them about their role

during an emergency. All nearby people shall be given training on do’s and don’ts during an emergency

situation.

Distillery Industry (Ethanol Plant) is associated with potential hazards to the employee and environment.

As the hazards involved during operation and production activities will be known to the Management, all

required mitigation measures shall be implemented in time to avoid the emergency situation from the

arising. Unfortunately, if there is any emergency onsite of offsite, it will be tackled effectively due to the

availability of required resources at the site. Similarly, all the concern staff and members of the Teams

shall be trained appropriately to tackle the emergencies in the plant. By knowing the type of emergency

situation that may arise during the operation of the plant, appropriate control measures will be

implemented to reduce the gravity of the emergencies. Similarly, to avoid the emergency situation, all

required mitigation measures will be implemented as recommended.